Crate assemblies for transporting spools of glass

ABSTRACT

A crate assembly includes an external crate assembly (12) having a top (16), a bottom (18), sides (20, 21) and ends (22, 23). An internal spool support assembly (14) is located within the external crate assembly (12). The internal spool support assembly (14) includes a lower spool support structure (54). The lower spool support structure (54) includes a first lower spool support assembly (58) located at one of the ends (22, 23) of the external crate assembly (12). A second lower spool support assembly (60) is located at an opposite one of the ends (22, 23) of the external crate assembly (12). The first lower spool support assembly (58) is separated from the second lower spool support assembly (60) such that the first and second lower spool assemblies (58, 60) may move relative to each other.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority under 35 U.S.C. § 119 ofU.S. Provisional Application Ser. No. 62/427,404 filed on Nov. 29, 2016,the content of which is relied upon and incorporated herein by referencein its entirety.

TECHNICAL FIELD

The present specification generally relates to crate assemblies for usein transporting spools of ultra-thin glass and to methods oftransporting spools of ultra-thin glass using the bulk spool crateassemblies.

BACKGROUND

Current shipping crates used to ship bulk flexible glass wound on aspool may not adequately protect glass spools from damage and theresulting lower utilization of produced glass. Glass spools may besubjected to unintended levels of acceleration and vibration duringshipping that can result in damage to the glass and cause increased costto the manufacturer or customer. For example, relatively high levels ofacceleration or vibration may occur during an impact to the shippingcrates such as when crates are dropped or mishandled e.g., with aforklift.

Accordingly, a need exists for crate assemblies and methods oftransporting spools of ultra-thin glass that can reduce acceleration andvibration experienced by the glass product due to an impact, which canreduce a likelihood of damage to the glass.

SUMMARY

According to a first embodiment, a crate assembly comprises:

an external crate assembly having a top, a bottom, sides and ends, thesides and ends extending between the top and the bottom;

an internal spool support assembly located within the external crateassembly, the internal spool support assembly comprising a lower spoolsupport structure comprising:

-   -   a first lower spool support assembly located at one of the ends        of the external crate assembly, the first lower spool support        assembly having a spool-core receiving notch extending        therethrough and sized to receive a spool core end; and    -   a second lower spool support assembly located at an opposite one        of the ends of the external crate assembly, the second lower        spool support assembly having a spool-core receiving notch        extending therethrough and sized to receive an opposite spool        core end such that the spool core is arranged substantially        perpendicular to the ends;

wherein the first lower spool support assembly is separated from thebottom of the external crate assembly by an isolation pad positionedbetween the first lower spool support assembly and the bottom of theexternal crate assembly and the second lower spool support assembly isseparated from the bottom of the external crate assembly by an isolationpad positioned between the second lower spool support assembly and thebottom of the external crate assembly, and the first lower spool supportassembly is separated from the second lower spool support assembly suchthat the first and second spool support assemblies are movable relativeto each other.

According to a second embodiment, there is provided the crate assemblyof embodiment 1, wherein the first lower spool support assembly isseparated from the sides of the external crate assembly using isolationpads located between the first lower spool support assembly and thesides.

According to a third embodiment, there is provided the crate assembly ofembodiment 1 or embodiment 2, wherein the second lower spool supportassembly is separated from the sides of the external crate assemblyusing isolation pads located between the second lower spool supportassembly and the sides.

According to a fourth embodiment, there is provided the crate assemblyof any one of embodiments 1-3, wherein the first lower spool supportassembly is separated from the one of the ends using an isolation padlocated between the first lower spool support assembly and the one ofthe ends.

According to a fifth embodiment, there is provided the crate assembly ofembodiment 4, wherein the first lower spool support assembly isseparated from the one of the ends using multiple, vertically orientedisolation pads that are spaced-apart from one another in a lateraldirection.

According to a sixth embodiment, there is provided the crate assembly ofembodiment 4 or embodiment 5, wherein the second lower spool supportassembly is separated from the opposite one of the ends using anisolation pad located between the second spool support assembly and theopposite one of the ends.

According to a seventh embodiment, there is provided the crate assemblyof embodiment 6, wherein the second lower spool support assembly isseparated from the opposite one of the ends using multiple, verticallyoriented isolation pads that are spaced-apart from one another in alateral direction.

According to an eighth embodiment, there is provided the crate assemblyof any one of embodiments 1-7, further comprising an upper spool supportassembly comprising:

a first upper spool support assembly located at the one of the ends ofthe external crate assembly; and

a second upper spool support assembly located at the opposite one of theends of the external crate assembly;

wherein the first upper spool support assembly is separated from the topof the external crate assembly by an isolation pad positioned betweenthe first upper spool support assembly and the top of the external crateassembly and the second upper spool support assembly is separated fromthe top of the external crate assembly by an isolation pad positionedbetween the second upper spool support assembly and the top of theexternal crate assembly.

According to a ninth embodiment, there is provided the crate assembly ofembodiment 8, wherein the first upper spool support assembly isseparated from the one of the ends an isolation pad located between thefirst lower spool support assembly and the one of the ends.

According to a tenth embodiment, there is provided the crate assembly ofembodiment 9, wherein the first upper spool support assembly isseparated from the one of the ends using multiple, vertically orientedisolation pads that are spaced-apart from one another in a lateraldirection.

According to an eleventh embodiment, there is provided the crateassembly of embodiment 9 or embodiment 10, wherein the second upperspool support assembly is separated from the opposite one of the endsusing an isolation pad located between the second upper support assemblyand the opposite one of the ends.

According to a twelfth embodiment, there is provided the crate assemblyof embodiment 11, wherein the second upper spool support assembly isseparated from the opposite one of the ends using multiple, verticallyoriented isolation pads that are spaced-apart from one another in alateral direction.

According to a thirteenth embodiment, there is provided the crateassembly of any one of embodiments 1-12, wherein the isolation padscomprise polyethylene foam.

According to a fourteenth embodiment, there is provided the crateassembly of any one of embodiments 1-13, further comprising a spool ofultra-thin glass weighing 227 kg weight (500 pounds) or more locatedtherein, the spool of ultra-thin glass including a spool core having afirst core end received within the spool-core receiving notch of thefirst lower spool support assembly and an opposite second core endreceived within the spool-core receiving notch of the second lower spoolsupport assembly, the isolation pad positioned between the first lowerspool support assembly and the bottom maintaining separation between thefirst lower spool support assembly and the bottom with the first coreend received within the spool-core receiving notch of the first lowerspool support assembly.

According to a fifteenth embodiment, a method of shipping a spool ofultra-thin glass comprises:

placing a core into a crate assembly, the core comprising a first coreend, a second core end, and ultra-thin glass rolled thereon, the crateassembly comprising:

-   -   an external crate assembly having a top, a bottom, sides and        ends, the sides and ends extending between the top and the        bottom;    -   an internal spool support assembly located within the external        crate assembly, the internal spool support assembly comprising a        lower spool support structure comprising:        -   a first lower spool support assembly located at one of the            ends of the external crate assembly, the first lower spool            support assembly having a spool-core receiving notch            extending therethrough and sized to receive a spool core            end; and        -   a second lower spool support assembly located at an opposite            one of the ends of the external crate assembly, the second            lower spool support assembly having a spool-core receiving            notch extending therethrough and sized to receive an            opposite spool core end such that the spool core is arranged            substantially perpendicular to the ends;    -   wherein the first lower spool support assembly is separated from        the bottom of the external crate assembly by an isolation pad        positioned between the first lower spool support assembly and        the bottom of the external crate assembly and the second lower        spool support assembly is separated from the bottom of the        external crate assembly by an isolation pad positioned between        the second lower spool support assembly and the bottom of the        external crate assembly, and the first lower spool support        assembly is separated from the second lower spool support        assembly such that the first and second spool assemblies are        movable relative to each other;

locating the first core end of the spool core within the spool-corereceiving notch of the first lower spool support assembly; and

locating the second core end of the spool core within the spool-corereceiving notch of the second lower spool support assembly.

According to a sixteenth embodiment, there is provided the method ofembodiment 15, wherein the first lower spool support assembly isseparated from the sides of the external crate assembly using isolationpads located between the first lower spool support assembly and thesides.

According to a seventeenth embodiment, there is provided the method ofembodiment 15 or 16, wherein the second lower spool support assembly isseparated from the sides of the external crate assembly using isolationpads located between the second lower spool support assembly and thesides.

According to an eighteenth embodiment, there is provided the method ofany one of embodiments 15-17, wherein the first lower spool supportassembly is separated from the one of the ends using an isolation padlocated between the first lower spool support assembly and the one ofthe ends.

According to a nineteenth embodiment, there is provided the method ofembodiment 18, wherein the first lower spool support assembly isseparated from the one of the ends using multiple, vertically orientedisolation pads that are spaced-apart from one another in a lateraldirection.

According to a twentieth embodiment, there is provided the method ofembodiment 18 or embodiment 19, wherein the second lower spool supportassembly is separated from the opposite one of the ends using anisolation pad located between the second spool support assembly and theopposite one of the ends.

According to a twenty-first embodiment, there is provided the method ofembodiment 20, wherein the second lower spool support assembly isseparated from the opposite one of the ends using multiple, verticallyoriented isolation pads that are spaced-apart from one another in alateral direction.

According to a twenty-second embodiment, there is provided the method ofany one of embodiments 15-21, further comprising an upper spool supportassembly comprising:

a first upper spool support assembly located at the one of the ends ofthe external crate assembly; and

a second upper spool support assembly located at the opposite one of theends of the external crate assembly;

wherein the first upper spool support assembly is separated from the topof the external crate assembly by an isolation pad positioned betweenthe first upper spool support assembly and the top of the external crateassembly and the second upper spool support assembly is separated fromthe top of the external crate assembly by an isolation pad positionedbetween the second upper spool support assembly and the top of theexternal crate assembly.

According to a twenty-third embodiment, there is provided the method ofany one of embodiments 15-22, wherein the isolation pads comprisepolyethylene foam.

According to a twenty-fourth embodiment, there is provided the method ofany one of embodiments 15-23, wherein the spool of ultra-thin glassweighs 227 kg weight (500 pounds) or greater, the isolation padpositioned between the first lower spool support assembly and the bottomseparating the first lower spool support assembly and the bottom withthe first core end received within the spool-core receiving notch of thefirst lower spool support assembly.

Additional features and advantages will be set forth in the detaileddescription which follows, and in part will be readily apparent to thoseskilled in the art from the description or recognized by practicing theembodiments as exemplified in the written description and the appendeddrawings and as defined in the appended claims. It is to be understoodthat both the foregoing general description and the following detaileddescription are merely exemplary, and are intended to provide anoverview or framework to understanding the nature and character of theclaims.

The accompanying drawings are included to provide a furtherunderstanding of principles of the present disclosure, and areincorporated in and constitute a part of this specification. Thedrawings illustrate one or more embodiment(s), and together with thedescription serve to explain, by way of example, principles andoperation of the embodiments described herein. It is to be understoodthat various features disclosed in this specification and in thedrawings can be used in any and all combinations.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a perspective view of a bulk crate assembly for shippingultra-thin glass spools, according to one or more embodiments shown anddescribed herein;

FIG. 2 depicts a side view of the bulk crate assembly of FIG. 1 with atop and side removed, according to one or more embodiments shown anddescribed herein;

FIG. 3 depicts an end view of the crate assembly of FIG. 1 with upperand lower outer wall members removed, according to one or moreembodiments shown and described herein;

FIG. 4 depicts an end view of the crate assembly of FIG. 1 with upperand lower outer wall members removed, according to one or moreembodiments shown and described herein; and

FIG. 5 depicts a section view of the bulk crate assembly of FIG. 1 witha spool of ultra-thin glass, according to one or more embodiments shownand described herein.

DETAILED DESCRIPTION

In the following detailed description, for purposes of explanation andnot limitation, example embodiments disclosing specific details are setforth to provide a thorough understanding of various principles of thepresent disclosure. However, it will be apparent to one having ordinaryskill in the art, having had the benefit of the present disclosure, thatthe present disclosure may be practiced in other embodiments that departfrom the specific details disclosed herein. Moreover, descriptions ofwell-known devices, methods and materials may be omitted so as not toobscure the description of various principles of the present disclosure.Finally, wherever applicable, like reference numerals refer to likeelements.

As used herein, the term “about” means that amounts, sizes,formulations, parameters, and other quantities and characteristics arenot and need not be exact, but may be approximate and/or larger orsmaller, as desired, reflecting tolerances, conversion factors, roundingoff, measurement error and the like, and other factors known to those ofskill in the art. When the term “about” is used in describing a value oran end-point of a range, the disclosure should be understood to includethe specific value or end-point referred to. Whether or not a numericalvalue or end-point of a range in the specification recites “about,” thenumerical value or end-point of a range is intended to include twoembodiments: one modified by “about,” and one not modified by “about.”It will be further understood that the endpoints of each of the rangesare significant both in relation to the other endpoint, andindependently of the other endpoint.

Directional terms as used herein—for example up, down, right, left,front, back, top, bottom—are made only with reference to the figures asdrawn and are not intended to imply absolute orientation.

Unless otherwise expressly stated, it is in no way intended that anymethod set forth herein be construed as requiring that its steps beperformed in a specific order. Accordingly, where a method claim doesnot actually recite an order to be followed by its steps or it is nototherwise specifically stated in the claims or descriptions that thesteps are to be limited to a specific order, it is no way intended thatan order be inferred, in any respect. This holds for any possiblenon-express basis for interpretation, including: matters of logic withrespect to arrangement of steps or operational flow; plain meaningderived from grammatical organization or punctuation; the number or typeof embodiments described in the specification.

As used herein, the singular forms “a,” “an” and “the” include pluralreferents unless the context clearly dictates otherwise. Thus, forexample, reference to a “component” includes embodiments having two ormore such components, unless the context clearly indicates otherwise.

Embodiments described herein relate generally to crate assemblies foruse in transporting spools of ultra-thin glass and to methods oftransporting spools of ultra-thin glass using the crate assemblies. Thecrate assemblies include an external crate assembly that has an internalspool support assembly located therein. The internal spool supportassembly includes isolation pads positioned between the internal spoolsupport assembly and the external crate assembly to facilitate dampedmovement of the internal spool support assembly relative to the externalcrate assembly. This damped movement of the internal spool supportassembly within the external crate assembly can allow the spool ofultra-thin glass to float within the external crate assembly. Such afloating arrangement for the spool of ultra-thin glass within theexternal crate assembly can reduce acceleration and vibrationexperienced by the spool of ultra-thin glass due to, for example, animpact to the external crate assembly during an impact event.

Without wishing to be bound by theory, it has been discovered thatspools of ultra-thin glass (e.g., glass of about 0.3 mm or less inthickness) within conventional shipping crates can experience damageunder accelerations of about 70 times the acceleration due to gravityduring impact testing. On the other hand, it is believed that spools ofultra-thin glass exhibit significantly reduced likelihood of damageunder accelerations of less than or equal to about 20 times theacceleration due to gravity. Such reduced accelerations can beaccomplished by applying a smaller force to the spool of ultra-thinglass over a longer period of time compared to a larger force over ashorter period of time.

As used herein, the term “longitudinal direction” refers to theelongated direction or lengthwise direction of the crate assembly (i.e.,in the +/−X-direction of the coordinate axes depicted in the figures).The term “lateral direction” refers to the cross-wise direction of thecrate assembly (i.e., in the +/−Y-direction of the coordinate axesdepicted in the figures), and is transverse to the longitudinaldirection. The term “vertical direction” refers to the upward-downwarddirection of the crate assembly (i.e., in the +/−Z-direction of thecoordinate axes depicted in the figures).

Referring to FIG. 1, a crate assembly 10 includes an external crateassembly 12 and an internal spool support assembly 14 located within theexternal crate assembly 12. The external crate assembly 12 and internalspool support assembly 14 together form an upper crate assembly 15 and alower crate assembly 17. The external crate assembly 12 includes a top16, a bottom 18, and sides 20, 21 and ends 22, 23 that extend betweenthe top 16 and the bottom 18. Located on the top 16 of the externalcrate assembly are guide members 24. The guide members 24 include alengthwise extending portion 26 that extends in the longitudinaldirection and a widthwise extending portion 28 that extends in thelateral direction across a gap 30 between the lengthwise extendingportions 26 and the sides 20 and 21. The guide members 24 and resultinggaps 30 can facilitate stacking and securing crate assemblies 10, one ontop of another for bulk shipping of the crate assemblies 10, forexample, within a cargo container. Crate assemblies 10 may be shipped instacks from one to eight crates high.

The bottom 18 includes support members 32 upon which the bottom 18 canrest elevated from the ground or floor. Spaces 34 between adjacent onesof the support member 32 can be sized to allow forks of a forklift to beinserted therein for a lifting and transport operation. The supportmembers 32 extend lengthwise along the bottom 18 in the longitudinaldirection. Widths of the support members 32 in the transverse directionare sized to be received by the gaps 30 between the lengthwise extendingportions 26 and the sides 20 and 22 to facilitate stacking of the crateassemblies 10.

The external crate assembly 12 includes the ends 22 and 23. The ends 22and 23 each include a lower outer wall member 36 connected to the bottom18 and an upper outer wall member 38 connected to the top 16 (only end22 can be seen). The lower outer wall member 36 includes a spool-corereceiving notch 46 sized to receive a spool core end. In someembodiments, the spool-core receiving notch 46 has an open side 48closed by a bottom ledge 50 of the upper outer wall member 38. The upperouter wall member 38 may include handles 52 (e.g., openings) that canfacilitate manual removal of the upper crate assembly 15 from the lowercrate assembly 17, e.g., to access the spool of ultra-thin glass locatedtherein.

Referring to FIG. 2, the crate assembly 10 is illustrated with the top16 and side 20 removed to show the internal spool support assembly 14within the volume 40. The internal spool support assembly 14 includes alower spool support structure 54 and an upper spool support structure56. The lower spool support structure 54 includes a first lower spoolsupport assembly 58 located at the end 22 and a second lower spoolsupport assembly 60 located at the opposite end 23 of the external crateassembly 12. The first and second lower spool support assemblies 58 and60 are spaced-apart from one another and disconnected such that they canmove relative to one another during use. The first lower spool supportassembly 58 includes vertically arranged, side-by-side support members62 and 64 that together form an end support structure 65 for supportinga spool core end of a spool of ultra-thin glass. The support members 62and 64 are illustrated as being substantially planar board-likestructures and extend widthwise in the lateral direction between thesides 20 and 21 of the external crate assembly 12. It should be notedthat while two support members 62 and 64 are illustrated, there may bemore or less than two support members, depending on the size and weightof the spool of ultra-thin glass to be transported. Each support member62 and 64 includes a spool-core receiving notch 69 (FIG. 1) that alignswith the spool-core receiving notch 46 of the lower outer wall member36.

Similarly, the second lower spool support assembly 60 includesvertically arranged, side-by-side support members 66 and 68 thattogether form an end support structure 71 for supporting the spool coreend of the spool of ultra-thin glass. The support members 66 and 68 areillustrated as being substantially planar board-like structures andextend widthwise in the lateral direction between the sides 20 and 21 ofthe external crate assembly 12. As above, while two support members 66and 68 are illustrated, there may be more or less than two supportmembers, depending on the size and weight of the spool of ultra-thinglass to be transported. Each support member 66 and 68 includes aspool-core receiving notch 70 that aligns with a spool-core receivingnotch 72 of lower outer wall member 75. The spool-core receiving notches70 also align with the spool-core receiving notches 69 so that a centralaxis of the spool of the ultra-thin glass is substantially perpendicularto the ends 22 and 23 of the external crate assembly 12 when supportedby the first and second lower spool support assemblies 58 and 60.

The first lower spool support assembly 58 is separated from the bottom18 using a bottom isolation pad 76. The bottom isolation pad 76 may be asingle isolation pad that extends a majority or substantially all of awidth of the support members 62 and 64. The bottom isolation pad 76 mayalso extend across the entire thickness of both support members 62 and64 to support the support members 62 and 64 spaced-from the bottom 18.In some embodiments, multiple bottom isolation pads may be used. Thenumber and dimension of the bottom isolation pad 76 may be selecteddepending on the size and dimension of, for example, the spool of theultra-thin glass.

The first lower spool support assembly 58 may further be separated fromthe side 20 using side isolation pads 78 and 80. The side isolation pads78 and 80 may extend along only portions of the heights of the supportmembers 62 and 64. The side isolation pads 78 and 80 may also extendacross the entire thickness of both support members 62 and 64 to supportthe support members 62 and 64 spaced-from the side 20. In someembodiments, a single side isolation pad may be used that extends alongall or only some of the height of the support members 62 and 64. Thenumber and dimension of the side isolation pads 78 and 80 may beselected depending on the size and dimension of, for example, the spoolof the ultra-thin glass.

Referring to FIG. 3 illustrating the crate assembly 10 with the lowerouter wall member 36 and the upper outer wall member 38 removed, thefirst lower spool assembly 58 may also be separated from the end 22using end isolation pads 82, 84, 86 and 88. The end isolation pads 82,84, 86 and 88 may extend along a height of the support members 62 and 64and be sandwiched between the support member 64 and the lower outer wallmember 36 (FIG. 1). As can be seen, the end isolation pads 82, 84, 86and 88 extend vertically along a height of the support member 64.Multiple end isolation pads 82, 84, 86 and 88 are provided that are eachspaced from one another in the widthwise direction. While the endisolation pads 82, 84, 86 and 88 are illustrated as being elongated inthe vertical direction, they may be elongated in the widthwisedirection. For example, as an alternative to being spaced-apart in thewidthwise direction, the end isolation pads may extend laterally and bespaced-apart in the vertical direction. The number and dimension of theend isolation pads 82, 84, 86 and 88 may be selected depending on thesize and dimension of, for example, the spool of the ultra-thin glass.

Referring still to FIG. 3, the first lower spool support assembly 58 mayfurther be separated from the side 21 using side isolation pads 90 and92. The side isolation pads 90 and 92 may extend along only portions ofthe heights of the support members 62 and 64. The side isolation pads 90and 92 may also extend across the entire thickness of both supportmembers 62 and 64 to support the support members 62 and 64 spaced-fromthe side 21. In some embodiments, a single side isolation pad may beused that extends along all or only some of the height of the supportmembers 62 and 64. The number and dimension of the side isolation pads90 and 92 may be selected depending on the size and dimension of, forexample, the spool of the ultra-thin glass. As can be appreciated, theside isolation pads 78, 80, 90 and 92 isolate the first lower spoolsupport assembly 58 from opposite sides 20 and 21, the end isolationpads 82, 84, 86 and 88 isolate the first lower spool support assembly 58from the end 22 and the bottom isolation pad 76 isolates the first lowerspool support assembly 58 from the bottom 18.

Referring again to FIG. 2, the second lower spool support assembly 60 isseparated from the bottom 18 using a bottom isolation pad 106. Thebottom isolation pad 106 may be a single isolation pad that extends amajority or substantially all of a width of the support members 66 and68. The bottom isolation pad 106 may also extend across the entirethickness of both support members 66 and 68 to support the supportmembers 66 and 68 spaced-from the bottom 18. In some embodiments,multiple bottom isolation pads may be used. The number and dimension ofthe bottom isolation pad 106 may be selected depending on the size anddimension of, for example, the spool of the ultra-thin glass.

The second lower spool support assembly 60 may further be separated fromthe side 20 using side isolation pads 108 and 110. The side isolationpads 108 and 110 may extend along only portions of the heights of thesupport members 66 and 68. The side isolation pads 78 and 80 may alsoextend across the entire thickness of both support members 66 and 68 tosupport the support members 66 and 68 spaced-from the side 20. In someembodiments, a single side isolation pad may be used that extends alongall or only some of the height of the support members 66 and 68. Thenumber and dimension of the side isolation pads 78 and 80 may beselected depending on the size and dimension of, for example, the spoolof the ultra-thin glass.

Referring to FIG. 4, illustrating the crate assembly 10 with the lowerouter wall member 75 and the upper outer wall member 77 removed (FIG.2), the second lower spool assembly 60 may also be separated from theend 23 using end isolation pads 112, 114, 116 and 118. The end isolationpads 112, 114, 116 and 118 may extend along a height of the supportmembers 66 and 68 and be sandwiched between the support member 68 andthe lower outer wall member 75. As can be seen, the end isolation pads112, 114, 116 and 118 extend vertically along a height of the supportmember 68. Multiple end isolation pads 112, 114, 116 and 118 areprovided that are each spaced from one another in the widthwisedirection. While the end isolation pads 112, 114, 116 and 118 areillustrated as being elongated in the vertical direction, they may beelongated in the widthwise direction. For example, as an alternative tobeing spaced-apart in the widthwise direction, the end isolation padsmay extend laterally and be spaced-apart in the vertical direction. Thenumber and dimension of the end isolation pads 112, 114, 116 and 118 maybe selected depending on the size and dimension of, for example, thespool of the ultra-thin glass.

Referring still to FIG. 4, the second lower spool support assembly 60may further be separated from the side 21 using side isolation pads 120and 122. The side isolation pads 120 and 122 may extend along onlyportions of the heights of the support members 66 and 68. The sideisolation pads 120 and 122 may also extend across the entire thicknessof both support members 66 and 68 to support the support members 66 and68 spaced-from the side 21. In some embodiments, a single side isolationpad may be used that extends along all or only some of the height of thesupport members 66 and 68. The number and dimension of the sideisolation pads 120 and 122 may be selected depending on the size anddimension of, for example, the spool of the ultra-thin glass. As can beappreciated, the side isolation pads 108, 110, 120 and 122 isolate thesecond lower spool support assembly 60 from opposite sides 20 and 21,the end isolation pads 112, 114, 116 and 118 isolate the second lowerspool support assembly 60 from the end 23 and the bottom isolation pad106 isolates the second lower spool support assembly 60 from the bottom18.

Referring again to FIG. 2, the internal spool support assembly 14includes the upper spool support structure 56. The upper spool supportstructure 56 includes a first upper spool support assembly 126 locatedat the end 22 and a second upper spool support assembly 128 located atthe opposite end 23 of the external crate assembly 12. The first andsecond upper spool support assemblies 126 and 128 are spaced-apart fromone another and disconnected such that they can move relative to oneanother during use. The first upper spool support assembly 126 includesvertically arranged, side-by-side support members 130 and 132 thattogether form an end support structure 134 for supporting the spool coreend of the spool of ultra-thin glass from above. The support members 130and 132 are illustrated as being substantially planar and extendingwidthwise in the lateral direction between the sides 20 and 21 of theexternal crate assembly 12. It should be noted that while two supportmembers 130 and 132 are illustrated, there may be more or less than twosupport members, depending on the size and weight of the spool ofultra-thin glass to be transported. Each support member 130 and 132includes a lower edge 135 that engages the support members 62 and 64 ofthe first lower support assembly 58 thereby enclosing their respectivespool-core receiving notches 69.

Similarly, the second upper spool support assembly 128 includesvertically arranged, side-by-side support members 136 and 138 thattogether form an end support structure 140 for supporting the spool coreend of the spool of ultra-thin glass. The support members 136 and 138are illustrated as being substantially planar and extend widthwise inthe lateral direction between the sides 20 and 21 of the external crateassembly 12. As above, while two support members 136 and 138 areillustrated, there may be more or less than two support members,depending on the size and weight of the spool of ultra-thin glass to betransported. Each support member 136 and 138 includes a lower edge 141that engages the support members 66 and 68 of the second lower supportassembly 60 thereby enclosing their respective spool-core receivingnotches 70.

The first upper spool support assembly 126 is separated from the top 16using a top isolation pad 142. The top isolation pad 142 may be a singleisolation pad that extends a majority or substantially all of a width ofthe support members 130 and 132. The top isolation pad 142 may alsoextend across the entire thickness of both support members 130 and 132to support the support members 130 and 132 spaced-from the top 16. Insome embodiments, multiple top isolation pads may be used. The numberand dimension of the top isolation pad 142 may be selected depending onthe size and dimension of, for example, the spool of the ultra-thinglass.

Unlike the first lower spool support assembly 58, the first upper spoolsupport assembly 126 may not include side isolation pads that separatethe first upper spool support assembly 126 from the sides 20 and 21. Inthis example, side isolation pads are not necessary on the upper spoolsupport assembly 126 because the first upper spool support assembly 126provides relatively little or no lateral support for the spool ofultra-thin glass as the spool core rests squarely within the spool-corereceiving notches 69 of the first lower spool support assembly 58. Inother embodiments, however, such as where the first upper spool supportassembly 126 includes a spool-core receiving notch, side isolation padsmay be used to isolate the first upper spool support assembly 126 fromthe sides 20 and 21 of the external crate assembly 12.

Referring again to FIG. 3, the first upper spool support assembly 126may also be separated from the end 22 using end isolation pads 156, 158,160 and 162. The end isolation pads 156, 158, 160 and 162 may extendalong a height of the support members 130 and 132 and be sandwichedbetween the support member 132 and the upper outer wall member 38 (FIG.1). As can be seen, the end isolation pads 156, 158, 160 and 162 extendvertically along a height of the support member 132 and are aligned withthe end isolation pads 82, 84, 86 and 88 thereby forming columns. Inother embodiments, the end isolation pads may not be aligned. Inalternative embodiments, the end isolation pads 156, 158, 160 and 162may be formed as one-piece with and an extension of the correspondingend isolation pads 82, 84, 86, and 88. Multiple end isolation pads 156,158, 160 and 162 are provided that are each spaced from one another inthe widthwise direction. While the end isolation pads 156, 158, 160 and162 are illustrated as being elongated in the vertical direction, theymay be elongated in the widthwise direction. For example, as analternative to being spaced-apart in the widthwise direction, the endisolation pads may extend laterally and be spaced-apart in the verticaldirection. The number and dimension of the end isolation pads 156, 158,160 and 162 may be selected depending on the size and dimension of, forexample, the spool of the ultra-thin glass. As can be appreciated, theend isolation pads 156, 158, 160 and 162 isolate the first upper spoolsupport assembly 126 from the end 22 and the top isolation pad 142isolates the first upper spool support assembly 126 from the top 16.

Referring again to FIG. 2, the second upper spool support assembly 128is separated from the top 16 using a top isolation pad 166. The topisolation pad 166 may be a single isolation pad that extends a majorityor substantially all of a width of the support members 136 and 138. Thetop isolation pad 166 may also extend across the entire thickness ofboth support members 136 and 138 to support the support members 136 and138 spaced-from the top 16. In some embodiments, multiple top isolationpads may be used. The number and dimension of the top isolation pad 166may be selected depending on the size and dimension of, for example, thespool of the ultra-thin glass.

Unlike the second lower spool support assembly 60, the second upperspool support assembly 128 may not include side isolation pads thatseparate the second upper spool support assembly 128 from the sides 20and 21. As noted above regarding the upper spool supporting assembly126, side isolation pads are not necessary on upper spool supportingassembly 128 because the second upper spool support assembly 128provides relatively little or no lateral support for the spool ofultra-thin glass as the spool core rests squarely within the spool-corereceiving notches 70 of the second lower spool support assembly 60. Inother embodiments, however, such as where the second upper spool supportassembly 128 includes a spool-core receiving notch, side isolation padsmay be used to isolate the second upper spool support assembly 128 fromthe sides 20 and 21 of the external crate assembly 12.

Referring again to FIG. 4, the second upper spool support assembly 128may also be separated from the end 23 using end isolation pads 170, 172,174 and 176. The end isolation pads 170, 172, 174 and 176 may extendalong a height of the support members 136 and 138 and be sandwichedbetween the support member 138 and the upper outer wall member 77. Ascan be seen, the end isolation pads 170, 172, 174 and 176 extendvertically along a height of the support member 138 and are aligned withthe end isolation pads 112, 114, 116 and 118 thereby forming columns. Inother embodiments, the end isolation pads may not be aligned. In someembodiments, the end isolation pads 170, 172, 174 and 176 may be formedas one-piece with and an extension of the corresponding end isolationpads 112, 114, 116 and 118. Multiple end isolation pads 170, 172, 174and 176 are provided that are each spaced from one another in thewidthwise direction. While the end isolation pads 170, 172, 174 and 176are illustrated as being elongated in the vertical direction, they maybe elongated in the widthwise direction. For example, as an alternativeto being spaced-apart in the widthwise direction, the end isolation padsmay extend laterally and be spaced-apart in the vertical direction. Thenumber and dimension of the end isolation pads 170, 172, 174 and 176 maybe selected depending on the size and dimension of, for example, thespool of the ultra-thin glass. As can be appreciated, the end isolationpads 170, 172, 174 and 176 isolate the second upper spool supportassembly 128 from the end 23 and the top isolation pad 166 isolates thesecond upper spool support assembly 128 from the top 16.

Referring to FIG. 5, the crate assembly 10 is illustrated including theexternal crate assembly 12 and the internal spool support assembly 14. Aspool 200 of ultra-thin glass is supported by the internal spool supportassembly 14. The spool 200 of ultra-thin glass may weigh from about 181kg (400 pounds) to about 362 kg (800 pounds), such as about 227 kgweight (500 pounds) or more, such as about 272 kg (600 pounds). Thespool 200 includes a spool core 202 and spool flanges 204 and 206 thatare located at opposite ends 208 and 210 of the wound, ultra-thin glass212. Spool core ends 214 and 216 protrude outwardly beyond the spoolflanges 204 and 206. The spool core end 214 is received by thespool-core receiving notches 69 of the first lower spool supportassembly 58 and spool core end 216 is received by the spool-corereceiving notches 70 of the second lower spool support assembly 60. Insome embodiments, spool flanges 204, 206, need not be present.

As can be seen, even with the weight of the spool 200 present, thebottom isolation pads 76 and 106 can maintain separation of the firstand second lower spool support assemblies 58 and 60 from the bottom 16of the external crate assembly 12. The isolation pads may be formed of amaterial of suitable density to absorb the vibration, shock, andacceleration of the spool. In certain embodiments, this material may befrom about 0.254 cm to about 12.7 cm (0.1 inch to 5 inches) thick. Inother embodiments, the material may be from about 0.5 cm to about 10.2cm (0.2 inch to 4 inches) thick. In still other embodiments, thismaterial may be from about 0.76 cm to about 7.6 cm (0.3 inch to 3inches) thick. In yet further embodiments, this material may be fromabout 2 cm to about 5 cm (0.8 to 2 inches) thick depending on thelocation of the material in the crate. The material in certainembodiments may comprise a polyethylene foam, such as commerciallyavailable as DOW Ethafoam HS 900 and the like.

Tests standardized by the International Safe Transit Association(“ISTA”) Procedure 3B may be used to test the forces acting on the crateassembly. Procedure 3B is a general simulation test forpackaged-products shipped through a motor carrier (truck) deliverysystem, where different types of packaged-products, often from differentshippers and intended for different ultimate destinations, are mixed inthe same load. This type of shipment is called LTL(less-than-truckload).

To assemble various embodiments, a manufacturer may start with thebottom. The bottom may be a thin, substantially flat board selected tosupport the external crate assembly, the upper and lower spool supportstructures and the bulk spool. The bottom may be made from wood,plastic, metal, or the like. Structure may be added to the bottom toform slots for the insertion of a fork lift's forks and to make theexternal crate assembly stackable. These slots may make transfer andcarrying of the crates via forklift or other suitable carrier moreefficient. Certain embodiments of the crate assembly may ship incontainers in which they are stacked from one to eight crates high.

Attached to the bottom may be the remaining external crate assemblyincluding four substantially planar sides that may make up the wallsextending between the top and bottom pieces of the external crateassembly. These sides may be arranged such that they form a rectangularshaped box, each side being substantially orthogonal to the other sideson either side of it. These sides may be made of wood, plastic, metal,or any other suitable material. These sides may be attached via nails,screws, bolts, brackets, or some other suitable methods, or may beattached via an epoxy. Some of the sides may be split into two sections,an upper and a lower, that are removably coupled to one another, suchthat the top part of the side may be permanently connected to theexternal assembly top and the bottom part of the side may be permanentlyconnected to the bottom of the external crate assembly. The sides maycontain handles, slots, or some other suitable means to make thehandling of the walls easier and more convenient for the users of thecrate assembly. Two opposite sides may have a spool-core receiving notchextending therethrough, this spool-core receiving notch designed suchthat the notch cradles a spool core end of the spool and inhibitsmovement of the spool during transport.

To assemble the isolation pads, the isolation pads may be adhered orotherwise connected to the external crate assembly at the variouslocations discussed above. The top section may be constructed in afashion similar to the bottom section, starting with a substantiallyflat piece of wood, plastic, metal, or the like and adding two or foursides, each substantially orthogonal to the sides surrounding it. Thesides may include pre-fabricated handles in the form of voids, or may beexternal to the wall structure in such form as a handle, rope, or thelike. These handles may be added to the walls of the top piece of theexternal crate assembly after the top piece has been removably connectedwith the bottom piece or before. Once the top section is constructed,isolation pads may be placed within the top section as described above.The upper and lower support structures may then be assembled to theirrespective top and bottom sections.

The ultra-thin flexible glass may have a thickness of about 0.3 mm orless including but not limited to thicknesses of, for example, about0.01-0.05 mm, about 0.05-0.1 mm, about 0.1-0.15 mm, about 0.15-0.3 mm,about 0.100 to about 0.200 mm, 0.3, 0.275, 0.25, 0.225, 0.2, 0.19, 0.18,0.17, 0.16, 0.15, 0.14, 0.13, 0.12, 0.11, 0.10, 0.09, 0.08 0.07, 0.06,0.05, 0.04, 0.03, 0.02, or 0.01 mm. The ultra-thin glass may be formedof glass, a glass ceramic, a ceramic material or composites thereof. Afusion process (e.g., downdraw process) that forms high quality flexibleglass can be used in a variety of devices and one such application isflat panel displays. Glass produced in a fusion process has surfaceswith superior flatness and smoothness when compared to glass produced byother methods. The fusion process is described in U.S. Pat. Nos.3,338,696 and 3,682,609. Other suitable glass forming methods include afloat process, updraw, down draw, press rolling, and slot draw methods.Additionally, the flexible glass may also contain anti-microbialproperties by using a chemical composition for the glass including an Agion concentration on the surface in the range greater than 0 to 0.047μg/cm², further described in U.S. Patent Application Publication No.2012/0034435 A1. The flexible glass may also be coated with a glazecomposed of silver, or otherwise doped with silver ions, to gain thedesired anti-microbial properties, as further described in U.S. PatentApplication Publication No. 2011/0081542 A1. Additionally, the flexibleglass may have a molar composition of 50% SiO₂, 25% CaO, and 25% Na₂O toachieve the desired anti-microbial effects.

The terms “substantial,” “substantially,” and variations thereof as usedherein are intended to note that a described feature is equal orapproximately equal to a value or description. For example, a“substantially planar” surface is intended to denote a surface that isplanar or approximately planar. Moreover, “substantially” is intended todenote that two values are equal or approximately equal. In someembodiments, “substantially” may denote values within about 10% of eachother, such as within about 5% of each other, or within about 2% of eachother.

While particular embodiments have been illustrated and described herein,it should be understood that various other changes and modifications maybe made without departing from the spirit and scope of the claimedsubject matter. Moreover, although various embodiments of the claimedsubject matter have been described herein, such embodiments need not beutilized in combination. It is therefore intended that the appendedclaims cover all such changes and modifications that are within thescope of the claimed subject matter.

1. A crate assembly comprising: an external crate assembly comprising atop, a bottom, sides and ends, the sides and ends extending between thetop and the bottom; an internal spool support assembly located withinthe external crate assembly, the internal spool support assemblycomprising a lower spool support structure comprising: a first lowerspool support assembly located at one of the ends of the external crateassembly, the first lower spool support assembly comprising a spool-corereceiving notch extending therethrough and sized to receive a spool coreend; and a second lower spool support assembly located at an oppositeone of the ends of the external crate assembly, the second lower spoolsupport assembly comprising a spool core receiving notch extendingtherethrough and sized to receive an opposite spool core end such thatthe spool core is arranged substantially perpendicular to the ends;wherein the first lower spool support assembly is separated from thebottom of the external crate assembly by an isolation pad positionedbetween the first lower spool support assembly and the bottom of theexternal crate assembly and the second lower spool support assembly isseparated from the bottom of the external crate assembly by an isolationpad positioned between the second lower spool support assembly and thebottom of the external crate assembly the first lower spool supportassembly being separated from the second lower spool support assemblysuch that the first and second spool support assemblies are movablerelative to one other.
 2. The crate assembly of claim 1, wherein thefirst lower spool support assembly is separated from the sides of theexternal crate assembly using isolation pads located between the firstlower spool support assembly and the sides.
 3. The crate assembly ofclaim 2, wherein the second lower spool support assembly is separatedfrom the sides of the external crate assembly using isolation padslocated between the second lower spool support assembly and the sides.4. The crate assembly of claim 1, wherein the first lower spool supportassembly is separated from the one of the ends using an isolation padlocated between the first lower spool support assembly and the one ofthe ends.
 5. The crate assembly of claim 4, wherein the first lowerspool support assembly is separated from the one of the ends usingmultiple, vertically oriented isolation pads that are spaced-apart fromone another in a lateral direction.
 6. The crate assembly of claim 4,wherein the second lower spool support assembly is separated from theopposite one of the ends using an isolation pad located between thesecond spool support assembly and the opposite one of the ends.
 7. Thecrate assembly of claim 6, wherein the second lower spool supportassembly is separated from the opposite one of the ends using multiple,vertically oriented isolation pads that are spaced-apart from oneanother in a lateral direction.
 8. The crate assembly of claim 1,further comprising an upper spool support assembly comprising: a firstupper spool support assembly located at the one of the ends of theexternal crate assembly; and a second upper spool support assemblylocated at the opposite one of the ends of the external crate assembly;wherein the first upper spool support assembly is separated from the topof the external crate assembly by an isolation pad positioned betweenthe first upper spool support assembly and the top of the external crateassembly and the second upper spool support assembly is separated fromthe top of the external crate assembly by an isolation pad positionedbetween the second upper spool support assembly and the top of theexternal crate assembly. 9-12. (canceled)
 13. The crate assembly ofclaim 1, wherein the isolation pads comprise polyethylene foam.
 14. Thecrate assembly of claim 1, further comprising a spool of ultra-thinglass weighing 227 kg weight (500 pounds) or more located therein, thespool of ultra-thin glass comprising a spool core comprising a firstcore end received within the spool-core receiving notch of the firstlower spool support assembly and an opposite second core end receivedwithin the spool-core receiving notch of the second lower spool supportassembly, the isolation pad positioned between the first lower spoolsupport assembly and the bottom maintaining separation between the firstlower spool support assembly and the bottom with the first core endreceived within the spool-core receiving notch of the first lower spoolsupport assembly.
 15. A method of shipping a spool of ultra-thin glass,the method comprising: placing a core into a crate assembly, the corecomprising a first core end, a second core end, and ultra-thin glassrolled thereon, the crate assembly comprising: an external crateassembly comprising a top, a bottom, sides and ends, the sides and endsextending between the top and the bottom; an internal spool supportassembly located within the external crate assembly, the internal spoolsupport assembly comprising a lower spool support structure comprising:a first lower spool support assembly located at one of the ends of theexternal crate assembly, the first lower spool support assemblycomprising a spool-core receiving notch extending therethrough and sizedto receive a spool core end; and a second lower spool support assemblylocated at an opposite one of the ends of the external crate assembly,the second lower spool support assembly comprising a spool-corereceiving notch extending therethrough and sized to receive an oppositespool core end such that the spool core is arranged substantiallyperpendicular to the ends; wherein the first lower spool supportassembly is separated from the bottom of the external crate assembly byan isolation pad positioned between the first lower spool supportassembly and the bottom of the external crate assembly and the secondlower spool support assembly is separated from the bottom of theexternal crate assembly by an isolation pad positioned between thesecond lower spool support assembly and the bottom of the external crateassembly, the first lower spool support assembly being separated fromthe second lower spool support assembly such that the first and secondspool assemblies are movable relative to each other; locating the firstcore end of the spool core within the spool-core receiving notch of thefirst lower spool support assembly; and locating the second core end ofthe spool core within the spool-core receiving notch of the second lowerspool support assembly. 16-21. (canceled)
 22. The method of claim 15,further comprising an upper spool support assembly comprising: a firstupper spool support assembly located at the one of the ends of theexternal crate assembly; and a second upper spool support assemblylocated at the opposite one of the ends of the external crate assembly;wherein the first upper spool support assembly is separated from the topof the external crate assembly by an isolation pad positioned betweenthe first upper spool support assembly and the top of the external crateassembly and the second upper spool support assembly is separated fromthe top of the external crate assembly by an isolation pad positionedbetween the second upper spool support assembly and the top of theexternal crate assembly.
 23. The method of claim 15, wherein theisolation pads comprise polyethylene foam.
 24. The method of claim 15,wherein the spool of ultra-thin glass weighs 227 kg weight (500 pounds)or more, the isolation pad positioned between the first lower spoolsupport assembly and the bottom separating the first lower spool supportassembly and the bottom with the first core end received within thespool-core receiving notch of the first lower spool support assembly.